Method of making pyro-resins



Nov. 10, 1936. N. K. CHANEY ET AL METHOD OF MAKING PYRO-RESINS Filed Sept. 14, 1952 2 Sheets-Sheet 2 0 HR 6 5 X .E 5 CW5 N 5 T R a K. 0 w 5 w o M I o A J mu NW W a m w m 5 6 m a n M M i #5 5 f f w DJ H w m: 0 o w w w w m m 8 ,w w w w w m o m kkwumw Patented Nov. 10, 1936 UNITED STATES METHOD OF MAKING PYRO-RESINS Newcomb K. Chaney,

Cleveland Heights, and

Wilb'ur B. Dexter, Lakewood, Ohio, assignors, by mesne assignments, to Union Carbide and Carbon Corporation, New York, N. Y., a corporation of New York Application September 14, 1932, Serial No. 633,054

7 Claims.

This invention relates to resins formed by the pyrolysis of numerous plastic resins. It has special reference to the preparation of difficultly fusible resins which can be moulded under heat and pressure, whereupon they become relatively stable as compared with the materials from which the pyro-resins were formed. While in many of the examples given herein the plastic resin formed by the polymerization of vinyl compounds, e. g. acetates-chlorides, or mixtures of the two, will be referred to, it is to be understood that our invention is in no way limited to the use of vinyl resins but includes the phthalic anhydride and glycerine condensation products,

, cumaron resins, low melting point phenolic condensation products and others.

An object of our invention is the preparation of infusible or difiicultly fusible pyro-derivatives of certain thermo-plastic resins, such as the vinyl resins and the others above mentioned. Another object of our invention is to deposit insoluble infusible pyro-resins in adherent continuous phase capable of functioning as impervious protective films, as bonding media in plastic compositions and as chemically resistant impregnating agents.

These and other objects of our invention will be evident from the following specification, having reference to the accompanying drawings in which Figs. 1 to 6 inclusive are curves showing 30 the loss in weight of various substances during their thermal treatment.

The resins formed by the condensation and/or polymerization of organic compounds may be divided roughly into two classes. The first of 35 these, typified by the high melting point phenolic-aldehyde resins, are not thermo-plastic, and give a high yield in the preparation of an infusible product. The other group, which includes the vinyl resins, Glyptal, the cumaron 0 resins and others, are thermo-plastic, have large weight losses upon conversion to aninfusible 1 product and have an increased thermal stability after conversion. 1

It has, in the past, been believed that the resins of the thermo-plastic group should not be subjected to high temperatures since the resulting product swelled, foamed or was distorted We have found that if this heating be controlled and proper provision made to allow the gases formed during the heating to escape, new and valuable products are obtained.

In the accompanying drawings the curves show the loss in weight of vinyl polymers upon heating. The abscissae represent time of heating in hours and the ordinates represent loss in weight in percent. Figures 1 to 3 represent the heat treatment of films containing 2% FeCls at' 225 C., Fig. 1 being for the resin formed by the polymerization of vinyl acetate, Fig. 2 for the resin formed by the polymerization of vinyl chloride and Fig. 3 for the resin formed by the conjoint polymerization of 4 parts vinyl chloride and 1 part vinyl acetate. Figures 4 to 6 represent the heat treatment at 200 C.; Fig. 4 being for a film composed of vinyl acetate resin with 1% FeCls; 5 Fig. 5 being for vinyl chloride resin, curve AA for the original powder treated with concentrated sulphuric acid, curve BB for a dried film treated with concentrated sulphuric acid, and curve 0-0 for a film containing 1% FeCls; and 10 Fig. 6 being for a resin formed by the conjoint polymerizationof {i parts vinyl'chloride and 1 part vinyl acetate, curve D-D for a dried film treated with concentrated sulphuric acid and curve E-E for a film containing 1% FeCla.

We have found that in the heat conversion of resins of the thermo-plastic type it is important that the heating be gradual. If the heating be sudden .a type of conversion occurs in which a greater part of the resin is volatilized, whereas 20 more gradual and prolonged heating at lower temperatures will yield a continuous adherent phase which may be carried to higher temperatures with relative impunity. This transformation is always accompanied, in the case of the resins prepared from vinyl esters, by the evolution of free acid during the pyro-condensation.

In order to permit the thermal decomposition to proceed with reasonable velocity at lower temperatures and to facilitate the formation of the pyro-resins in continuous phase, with lessened tendency to shrinkage, rupturing and cracking, we have found the use of catalytic acceleraters desirable. The most effective catalysts for this purpose are the chlorides of bismuth, iron and tin. Salts of such metals as zinc, aluminum, lead and the alkalis appear to promote thermal breakdown in many cases but exert undesirable effects, such as cracking and. embrittlement, giving a mechanically weak product. The catalysts favorable to the formation ofa strong pyro-resin appear to be limited to the salts of the metals which are somewhat soluble in the resin solvents employed. Under some conditions sulphuric acid has been found to be an effective catalyst for accelerating the condensation of the vinyl resins with heat, but there are difficulties in controlling its action which make it unsuitable for general use.

The curves shown in the figures illustrate the transition from thermally unstable, thermoplastic vinyl polymers to pyro-resins. The vertical portions of the curves show the actual transition while the horizontal portions show the thermal stability after the transition is complete. The curves given are for conversion in the presence of catalysts and the slope of the curve changes sharply. In the absence of a catalyst and at lower temperatures the same horizontal values are ultimately reached but the slope of the ascending curve is much more gradual. Analyses show that at or near the knee of these curves the elimination of the acetyl and chloride groups of the original vinyl polymer is substantially comtain difiiculties due to the copious evolution of gas during the early stages of the condensation reactions while the resins are still in-a fused thermo-plastic condition. Also the higher templete and also that an oxidation of the pyroperatures generally required for conversion and 5 resin has usually been effected. The resins show the greater weight-losses accompanying the reacan unsaturated character during the transition, tions greatly increase the tendency to shrinkage, possessing the property of readily decolorizing cracking and mechanical failure of the residual bromine water. pyro-resins on cooling. Hence the difliculties of The ratio of carbon to hydrogen atoms found obtaining such pyro-resin derivatives in contin- 10 by analysis of the pyro-resins after various stages uous phase for use as impervious films or as of heating varies from 4:3 to 4:5, averaging bonding media in plastic molded articles have about 4:4. The atomic ratio of carbon to oxygen been almost insuperable when large masses of varies from 4:1 to 4:2. Accordingly the following. resin or high binder ratios are employed, in fact general reaction is believed to approximately these difficulties have been sufficiently great to 15 indicate the nature of :the pyro-condensation: completely obscure the fact that a useful pyroresin formation is possible in the case of the (C4H5R2)'n+heat+oxygen (C4H402) n+2n(I-IR). so-called thermo-plastic resins. When the disa posal of large volumes of gaseous decomposition R indicates the acid rad al o the V y resin products is realized to be a condition precedent 2 As how y Figst Dy e a such .to the successful heat conversions of thermois n t c mp t y h at stable, u a s up v ry plastic resins of the vinyl and Glyptal types, slowly. on Prolonged heating at h gh temperait is obvious that modifications in the procedure u a lyses indicate the loss of hy ogen and may be devised which will permit of the utilizaoxygen, giving a product having the approximate tion of these resins in somewhat larger masses 25 general formula (C4H2O)n. During this proor higher ratios than have hereto been practical. longed vheating the resins shrink and crac and For example, an adsorbent for hydrochloric .acid become black y fl t d light; thin sections, may be incorporated in the mix or higher-presho v Still Show a red color y tra sm tted sures may be used to prevent bubble formation l hte y Considerable de mpos ion during condensation. Nevertheless, we believe 30 f -DY n-may occur before actual carthat the preferred commercial applications of bonization takes place. our new pyro-resin derivatives will lie in their use The following table gives the comparative in thin films and in lower. resin concentrations We Yields or complete conversion of thermoand that the commercial uses will depend upon plastic resins to the corresponding pyro-resins: the specific properties exhibite such pyroresins with respect to their mechanical strength, Time-hours bonding power in low concentrations, chemical Kind resin Temp range t catalyst ifig g i inertness and thermal stability.

As an example of the bonding power of these 1% 2% pyro-resins in low concentrations, brushes for C P t electric machinery were made using various types of binders. The binders were mixed with %ii t ?:l:::: 3?.5 3 graphite and ball milled for two hours and 9 Y Wymer' molded at pressures of 20 tons per square inch. vinymsmsm7 200-225 &5 catalyst 46 The vinyl resin was made by the conjoint polygg ggfiggf fg merization of 4 parts vinyl chloride and 1 part andglycerln) 200-220 32 45 vinyl acetate. In the table below, the figures g gi 9 under Fiber stress are net values after a de- Highrneltlngphcnolic 100-200 2 91.4 duction representing the strength of molded graphite with no binder. The Specific bonding The yield of pyro-resin from cumaron resin power is calculated by dividing the net fiber varies with the grade employed. Upon further stress by the percentage of resin employed.

Bakin 5532"??? 111 mm oiresin 3 31 5 5. 35 c 5 Observed Net 2.5 175 2.050 2050 1550 050 5 155 2. 001 4220 5220 540 10 155 1.073 5150 5150 520 2.5 245 2.055 2510 1510 540 5 225 2.015 5150 5150 1025 10 145 1.055 5155 5705 550 2.5 155 2. 050 4110 3110 1240 5 155 2.011 5400 4400 550 10 155 1.914 1220 5220 520 P55110115 high melting-. 2.5 205 2.051 2150 1150 450 Phenolic high melting 5 205 2. 024 2550 1550 .620 Phenolic high melting 10 205 1.953 4280 3280 330 heating the Glypta1" and vinyl resins continue This table shows that the specific bonding losing weight slowly but the phenolic resins gain power of these resins is much higher in relatively in weight by taking up oxygen. low concentrations, i. e. concentrations below The losses of from 20 to 60% of the weight of those heretofore used in the formation of the parent resin, which are necessary for the parbrushes, said low melting phenolic resins in the tial or complete pyro-conversion of the more past have been considered unsatisfactory for stable thermo-plastic resins obviously involve cerbrush bonding in the usual binder ratios. We

have found that the pyro-resins formed from low melting phenolic resins as well as the other pyroresins described herein show a continuous increase in specific bonding power in ratios below 10%.

The following is an example of a method of employing our invention in the production of carbon articles for use in the chemical industry. The carbon article as a vessel or tube is heated to C. and dipped in a 5% solution of a-resin fromed by the polymerization of vinyl chloride, the solvent being ethylene dichloride, and FeCl: equivalent to 1% by weight of the resin is added to the solution. The carbon article is dried rapidly in air and then placed in an oven at to C. for thirty minutes. The process is then repeated, in some cases a third repetition may be employed. After the second or third cycle as above a final heating at 200 C. for ten minutes is given. In case it is desired to coat an article which has been impregnated by some other method the amount of resin required is exceedingly small, often less than 1% by tively insoluble, pyro-resin which comprises heating a polymerized vinyl ester resin, at temperatures of from 200 to 250 C. in the presence of a catalyst selected from the group consisting of bismuth chloride, iron chloride and tin chloride until the resulting resin is relatively heat stable.

4. Method of preparing an insoluble infusible resin in continuous phase which consists in the thermal condensation of soluble thermo-plastic vinyl ester polymers in the presence of ferric chloride.

5. Process of forming diflicultly fusible, relatively insoluble pyro-resins which comprises heating a thermo-plastic vinyl ester polymer at temperatures of from 200 to 22510. from 5 to 7 hours in the presence of 2% of ferric chloride.

6. Process of forming diflicultly fusible relatively insoluble pyro-resins which comprises heating a vinyl ester polymer at temperatures of from to 225 C. in the presence of a chloride of the group of metals bismuth, iron and tin as a catalyst until at least 20% of said polymer has been eliminated in the form of an acid.

7. The method of forming insoluble infuslble pyro-resins which comprises the slow thermal decomposition and condensation of a low melting thermo-plastic vinyl ester resin in the presence of a chloride of the group of metals bismuth, iron and tin as a catalyst at a temperature above the melting point of the thermo-plastic resin, such,

condensation being characterized by a substantial loss in weight.

NEWCOMB K. CHANEY. W'ILBUR B. DEXTER. 

